Method of separating strands on a stretching surface

ABSTRACT

A method of increasing a width of a polymeric netting is disclosed. The method includes providing a polymeric netting having a length in a machine direction and running the polymeric netting in the machine direction onto a stretchable surface. The polymeric netting is in contact with the stretchable surface for a path length in the machine direction, and for at least a portion of the path length, the stretchable surface is stretching in the cross-machine direction. The traction between the polymeric netting and the stretchable surface during the stretching increases the width of at least a portion of the polymeric netting in the cross-machine direction.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. application Ser. No.13/891,287, filed May 10, 2013, now U.S. Pat. No. 9,314,962, thedisclosure of which is incorporated by reference in its entirety herein.

BACKGROUND

Slitting films during a continuous web process can be useful forproviding multiple smaller films of a desired size. In some applicationsit is desirable to use multiple strips of a film in a single product orto use an apertured film to enhance some performance aspect of theproduct.

Some hook members have been made with openings in the backing from whichthe hooks project. See, e.g., U.S. Pat. No. 4,001,366 (Brumlik) and U.S.Pat. No. 7,407,496 (Peterson), U.S. Pat. Appl. Pub. No. 2012/0204383(Wood et al.), and Int. Pat. Appl. Pub. Nos. WO 2005/122818 (Ausen etal.) and WO 1994/02091 (Hamilton). Also, laminates with separatedmechanical fastening strips are described in U.S. Pat. Appl. Pub. No.2007/0039142 (Petersen et al.) and Int. Pat. Appl. Pub. No.WO2011/163020 (Hauschildt et al.).

Some nonwoven materials have been made with openings. Such nonwovenshave been attached to elastics or extensible pleated backings. See,e.g., U. S. Pat. Appl. Pub. No. 2004/0147890 (Nakahata et al.), Int.Pat. Appl. Pub. No. WO 1996/10481 (Abuto et al.), and European PatentNo. EP 1066008 B1 (Eaton et al.). A reticulated mechanical fasteningpatch having loops is described in U.S. Pat. Appl. Pub. No. 2012/0330266(Zonneveld et al.).

SUMMARY

The present disclosure provides a method of separating strands of a slitweb using a web process. The process can be useful when the slit webincludes full slits or slits interrupted by intact bridging regions ofthe web. In some cases, the slit and spread web comprises openings madefrom multiple strands of a slit web with the strands attached to eachother at bridging regions of the web and separated from each otherbetween at least some of the bridging regions. The method includesspreading the slit web in a direction transverse to the slits by feedingthe slit web in the machine direction over a surface that stretches inthe cross-machine direction. A polymeric netting can also be widenedusing the method disclosed herein.

In one aspect, the present disclosure provides a method of separatingstrands of a slit web. The method includes providing a slit web having alength in a machine direction and running the slit web in the machinedirection onto a stretchable surface. The slit web includes multiplestrands provided by a plurality of slits extending in a first directionnot parallel to a cross-machine direction. The slit web is in contactwith the stretchable surface for a path length in the machine direction,and for at least a portion of the path length, the stretchable surfaceis stretching in the cross-machine direction. The traction between theslit web and the stretchable surface during the stretching at leastpartially separates at least some of the multiple strands of the slitweb in a second direction transverse to the first direction.

In another aspect, the present disclosure provides a method ofincreasing a width of a polymeric netting. The method includes providinga polymeric netting having a length in a machine direction and runningthe polymeric netting in the machine direction onto a stretchablesurface. The polymeric netting is in contact with the stretchablesurface for a path length in the machine direction, and for at least aportion of the path length, the stretchable surface is stretching in thecross-machine direction. Traction between the polymeric netting and thestretchable surface during stretching increases the width of at least aportion of the polymeric netting in the cross-machine direction.

In some embodiments of the foregoing aspects, miming the slit web or thepolymeric netting in the machine direction includes running the slit webor the polymeric netting over a roller comprising two rotating divergingdisks that are laterally spaced and have the stretchable surface betweenthem that stretches in the cross-machine direction for a portion of arotation of the two rotating diverging disks. In some embodiments, theslit web or polymeric netting has mechanical fastening elements (e.g.,male fastening elements) on at least one major surface. In theseembodiments, it should be understood that the method disclosed herein isalso a method of making a mechanical fastener.

The degree of separation of the strands in the methods disclosed hereinmay be adjusted based upon, for example, the desired appearance, weight,or cost in the final product.

The method disclosed herein may be useful, in some embodiments, formaking a reticulated mechanical fastening web, laminate, strip, or patchthat has a unique and attractive appearance. The method according to anyof the above aspects allows openings to be provided or widened in amechanical fastener without wasteful material loss. The openings canprovide breathability and flexibility to a mechanical fastener, whichmay enhance the comfort of the wearer, for example, of an absorbentarticle comprising the mechanical fastener made by the method disclosedherein. The mechanical fastener also is typically able to cover arelatively large area with a relatively small amount of material, whichmay lower its cost. Also, because of the large area that may be coveredby the mechanical fastener in an absorbent article, the mechanicalfastener may provide performance enhancement, for example, by resistshifting forces such as torsional or rotational forces caused bymovement of the wearer of the absorbent article. For example, in use,fitting an absorbent article such as a diaper about the wearer usuallyrequires the front and back waist portions of the diaper to overlap eachother. As the diaper is worn the movements of the wearer tend to causethe overlapping front and back waist portions to shift position relativeto each other. Unless such shifting is limited, the fit and containmentcharacteristics of the diaper may be degraded as the diaper is worn. Amechanical fastener made according to the present disclosure may provideimproved fit and closure stability by resisting such shifting because ofits relatively larger area and flexibility.

In this application, terms such as “a”, “an” and “the” are not intendedto refer to only a singular entity, but include the general class ofwhich a specific example may be used for illustration. The terms “a”,“an”, and “the” are used interchangeably with the term “at least one”.The phrases “at least one of” and “comprises at least one of” followedby a list refers to any one of the items in the list and any combinationof two or more items in the list. All numerical ranges are inclusive oftheir endpoints and non-integral values between the endpoints unlessotherwise stated.

The terms “first” and “second” are used in this disclosure. It will beunderstood that, unless otherwise noted, those terms are used in theirrelative sense only. For these components, the designation of “first”and “second” may be applied to directions, features, or componentsmerely as a matter of convenience in the description of one or more ofthe embodiments.

The terms “multiple” and “a plurality” refer to more than one.

The term “opening” should be understood to be a void space in the webthat is surrounded by web material. One opening is typically enclosed bytwo of the multiple strands.

The term “web” can refer to a continuous or running web, sometimeshaving an indefinite length. A web can typically be handled in aroll-to-roll process. The term “machine direction” (MD) as used aboveand below denotes the direction of a running web of material during amanufacturing process. When a strip is cut from a continuous web, themachine direction corresponds to the length “L” of the strip. As usedherein, the terms “machine direction” and “longitudinal direction” aretypically used interchangeably. The term “cross-machine direction” (CD)as used above and below denotes the direction which is essentiallyperpendicular to the machine direction. When a strip is cut from acontinuous web, the cross-machine direction corresponds to the width “W”of the strip. In some embodiments of the method disclosed herein, thefirst direction is the machine direction, and the second direction isthe cross-machine direction, but this is not a requirement.

The term “stretchable” refers to a material that can be extended orelongated in the direction of an applied stretching force withoutdestroying the structure of the material or material fibers. An elasticmaterial is a stretchable material that has recovery properties. In someembodiments, a stretchable material may be stretched to a length that isat least about 5, 10, 15, 20, 25, or 50 percent greater than its relaxedlength without destroying the structure of the material or materialfibers.

The term “elastic” refers to any material (such as a film that is 0.002mm to 0.5 mm thick) that exhibits recovery from stretching ordeformation. In some embodiments, a material may be considered to beelastic if, upon application of a stretching force, it can be stretchedto a length that is at least about 25 (in some embodiments, 50) percentlarger than its initial length and can recover at least 40, 50, 60, 70,80, or 90 percent of its elongation upon release of the stretchingforce.

The above summary of the present disclosure is not intended to describeeach disclosed embodiment or every implementation of the presentdisclosure. The description that follows more particularly exemplifiesillustrative embodiments. It is to be understood, therefore, that thedrawings and following description are for illustration purposes onlyand should not be read in a manner that would unduly limit the scope ofthis disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure may be more completely understood in consideration of thefollowing detailed description of various embodiments of the disclosurein connection with the accompanying drawings, in which:

FIG. 1A is a perspective view of one embodiment of diverging diskshaving a stretchable surface useful for carrying out the method of thepresent disclosure;

FIG. 1B is a perspective view of another embodiment of diverging diskshaving a stretchable surface useful for carrying out the method of thepresent disclosure;

FIG. 1C is a perspective view of an embodiment of another apparatushaving a stretchable surface useful for carrying out the method of thepresent disclosure;

FIG. 2A is a top view of an embodiment of a portion of a slit web usefulfor the method of making a mechanical fastener disclosed herein;

FIG. 2B is a top view of the portion of the slit web shown in FIG. 2Aafter it is spread according to the method disclosed herein;

FIG. 2C is a top view of the portion of the slit web of FIG. 2B after itis spread to a greater extent than shown in FIG. 2B;

FIG. 3A is a top view of another embodiment of a portion of a slit webuseful for the methods of making a mechanical fastener disclosed herein;

FIG. 3B is a top view of a portion of the slit web shown in FIG. 3Aafter it is spread according to the method disclosed herein;

FIG. 4A is a schematic top view of another embodiment of a portion of aslit web useful for the methods of making a mechanical fastenerdisclosed herein;

FIG. 4B is a schematic top view of the portion of the slit web of FIG.4A after it is spread according to the method disclosed herein;

FIG. 5 is a photograph illustrating twisting of strands of a slit webportion when it is spread apart; and

FIG. 6 is a diagrammatical view of an embodiment of the method ofseparating strands of a web disclosed herein.

DETAILED DESCRIPTION

Reference will now be made in detail to embodiments of the disclosure,one or more examples of which are illustrated in the drawings. Featuresillustrated or described as part of one embodiment can be used withother embodiments to yield still a third embodiment. It is intended thatthe present disclosure include these and other modifications andvariations.

FIG. 1A illustrates an example of a roller 100 useful for practicingsome embodiments of the method of the present disclosure. The rollerincludes two rotating diverging disks 101 that are laterally spaced. Theangle of the diverging disks 101 is set with adapters 103 that areangled on non-rotating shaft 105. In other embodiments, the shaft itselfmay be angled so that the disks diverge. Bearings 107 allow rotation ofthe diverging disks 101 on the non-rotating shaft 105. In theillustrated embodiment, each of the diverging disks includes multiplepins 109 that are useful for attaching a stretchable surface to thediverging disks 101. The stretchable surface is provided by stretchablebands 102 that are wrapped around corresponding pins 109 on the twodiverging disks 101. For example, a stretchable band 102 can be wrappedaround a pair of pins 109 on each of the diverging disks 101 where thetwo pairs on the two disks are aligned with each other along thecircumference of the disks. For visual clarity, only one circularstretchable band 102 is shown, which forms two separated stretchablesurfaces. However, in operation, multiple bands 102 around thecircumference of the diverging disks 101 may be useful to allow thecontinuous movement of the slit web.

In operation, band 102 stretches for 180 degrees of the rotation of thediverging disks 101 as it moves from the position where the disks areclosest together (at d1) to the position where the disks are furthestapart (at d2). The band 102 then retracts for 180 degrees of therotation of the diverging disks 101 as it moves from the position wherethe disks are furthest apart to the position where the disks are closesttogether. Multiple strands of a slit web or a polymeric netting (notshown in FIG. 1A) that come into contact with the band 102 at anyposition where the band is stretching will be spread apart in thedirection of the stretch. The slit web or polymeric netting may bepositioned to be in contact with the band 102 for any portion of therotation sufficient to at least partially separate at least some of themultiple strands of the slit web or widen openings in the netting. Insome embodiments, the slit web or polymeric netting may be in contactwith the roller 100 for the entire 180 degrees during which thestretchable surface is stretching. However, in some embodiments, it issufficient for the slit web or polymeric netting to remain in contactwith the roller for any rotation in a range from 1 to 180 degrees, forexample, up to 150, 120, 90, 60, 45, 30, 20, or 10 degrees of rotation,depending on the angle of the diverging disks 101 and the amount ofspreading desired in the slit web or netting. In other embodiments, theslit web or polymeric netting may remain in contact with the roller forany rotation in a range from 1 to 360 degrees depending on the amount ofspreading desired in the slit web or netting. The wrap angle can beadjusted depending on the amount of spreading desired in the process. Inany of these embodiments, the portion of the rotation that the slit webor polymeric netting is in contact with the roller can be considered thepath length.

Although bands 102 are useful as a stretchable surface on two rotatingdiverging disks 101 in the embodiment illustrated in FIG. 1A, otherstretchable surfaces may also useful in conjunction with rotatingdiverging disks 101. For example, non-circular bands or tubing mayprovide the stretchable surface. A coiled spring may also provide thestretchable surface. In another example, a stretchable sleeve attachedto the two diverging disks may be useful. Such a stretchable sleeve maybe supported by a surface between the two diverging disks if desired,but this is not a requirement. An example of a tubular sleeve and clampsthat may be adapted for use in the method according to the presentdisclosure is described in U.S. Pat. No. 4,862,565 (Damour). In thisreference, a spreader roll with a resilient sleeve has been reported tobe useful for removing wrinkles from fast traveling webs of fabric orplastic. Bands, tubing, coiled springs, or a sleeve may be attached tothe diverging disks by clamps, belts, or any other of a variety ofuseful methods including the pins 109 illustrated in FIG. 1A.

Any stretchable material that is capable of stretching and retractingduring the rotation of the diverging disks 101 may be useful for thestretchable surface 102 in the method according to the presentdisclosure. Such materials are elastic according to the definitionprovided above. In some embodiments, the stretchable surface is madefrom an elastomer. Examples of suitable classes of elastomers includenatural polyisoprene, synthetic polyisoprene, polybutadiene,poly(2,3-dimethylbutadiene), poly(butadiene-co-pentadiene), polysulfideelastomers, butyl rubber (e.g., polyisobutylene copolymers withisoprene), halogenated butyl rubber, polychloroprene,poly(butadiene-co-nitrile), hydrogenated nitrile-butadiene copolymers,and combinations thereof, any of which may be crosslinked by sulfur ornon-sulfur vulcanization. Further useful elastomers includeethylene-propylene copolymers, ethylene-propylene-diene terpolymers,sulfonated ethylene-propylene-diene terpolymers, chlorosulfonatedpolyethylenes, silicone elastomers, acrylic elastomers,ethylene-acrylate copolymers, fluorinated elastomers, fluorochlorinatedelastomers, fluorobrominated elastomers, and combinations thereof.Suitable elastomers also include thermoplastic elastomers, which aretypically made up of blocks of glassy or crystalline blocks (e.g.,polystyrene, poly(vinyltoluene), poly(t-butylstyrene), and polyester)and elastomeric blocks (e.g., polybutadiene, polyisoprene,ethylene-propylene copolymers, ethylene-butylene copolymers, polyetherester, and combinations thereof). Some thermoplastic elastomers arecommercially available, for example, poly(styrene-butadiene-styrene)block copolymers marketed by Kraton Performance Polymers, Houston, Tex.,under the trade designation “KRATON”. The diverging disks themselves aretypically made of metal (e.g., aluminum or steel) although othermaterials may be useful. Any of the embodiments of stretchable surfacesdescribed above (e.g., bands, tubing, and sleeves) may be made of any ofthese materials.

Typically, elastomeric materials such as any of those described aboveare considered “high-friction” materials and may allow for sufficienttraction between the slit web or polymeric netting and the stretchingsurface so that the slit web or netting spreads apart along with thestretching surface. The particular elastomer in the stretching surfacemay be selected to maximize the traction with the slit web or netting.However, in some embodiments, it may be useful to increase the tractionbetween a given elastomer and slit web or netting. This may be carriedout, for example, by increasing the machine direction tension on theweb. Any surface over which a web is bent or wrapped around is believedto impart a force on the web that is normal or perpendicular to the web.Increasing the machine direction tension will increase such a force.Also, the stretching surface may be provided with surface structure toincrease friction. For example, the presence of microstructures formedon the stretching surface can increase the coefficient of frictionbetween the stretching surface and the slit web or netting. Inembodiments in which the slit web is a mechanical fastening web, inparticular in which the mechanical fastening elements are male fasteningelements comprising upstanding posts having bases attached to the slitweb, the upstanding posts can be directed to face against the stretchingsurface to increase traction.

As described above, the shaft 105 shown in FIG. 1A is a non-rotatingshaft. In some embodiments, roller 100 is an idler roll, and therotation of the diverging disks is not driven by any means other thanthe movement of the slit web. In other embodiments, the diverging disksmay be driven by pulleys and belts or other suitable methods. In someembodiments, the rotation of the disks is driven from only one end ofthe shaft. For any of the embodiments in which the rotation of thediverging disks is driven, including embodiments in which the shafts aredriven as described below, a clutch mechanism may be useful foradjusting the speed of rotation.

Another embodiment of an apparatus including two diverging disks isillustrated in FIG. 1B. The apparatus includes two rotating divergingdisks 201 that are laterally spaced and mounted on individual rotatingshafts 205. The angle of the diverging disks 201 is adjusted byadjusting the angle of shafts 205. In FIG. 1B, like in FIG. 1A, each ofthe diverging disks includes multiple pins 209 that are useful forattaching a stretchable surface to the diverging disks 201. In theillustrated embodiment, each of the shafts is driven at a desired speedto cause rotation of the disks.

In FIG. 1B, a variety of stretchable surfaces are illustrated.Stretchable bands 202 a that are wrapped around corresponding pins 209on the two diverging disks 201 are like those shown in FIG. 1A. Hollowtubing 202 b is also illustrated as a stretchable surface. Theillustrated hollow tubing 202 b has an inner diameter that allows it tobe press fit on pins 209. Coiled spring 202 c is also illustrated as astretchable surface. The coiled spring may be metal (e.g., aluminum orsteel) although other materials may be useful. The coiled spring may becoated with a high-friction coating, if desired. The high-frictioncoating can be, for example, a coating of an elastomeric material asdescribed above, or a plasma coating known to provide a high-frictionsurface. Suitable plasma coatings include those available, for example,from Plasma Coating, Middlebury, Conn., under product familydesignations “10000” and “10015”. The coiled spring may also besurrounded with a piece of hollow tubing, for example, made from any ofthe elastomeric materials described above. A stretchable band 202 d thatis held flat against the peripheral surfaces of the diverging disks 201is also shown in FIG. 1B. In the illustrated embodiment, stretchableband 202 d is held against the peripheral surfaces using clamps 211 thatare attached to the diverging disks 201 with bolts 213, screws, or othermeans of attachment.

While any of the stretchable bands 202 a or 202 d, hollow tubing 202 b,or coiled spring 202 c may be the type of stretchable surface usedindividually in any of the embodiments of the method disclosed herein,it can also be useful to use different types of stretchable surfaces incombination. Accordingly, in some embodiments, the slit web or polymericnetting is run onto two different stretchable surfaces. In thisembodiment, “different” can indicate that the stretchable surfaces aremade from different materials or have a different configuration.Different types of stretchable surfaces may provide differentadvantageous properties, which may enhance different aspects of themethod described herein. Different types of stretchable surfaces mightbe selected, for example, for their elongation, stiffness, or frictionproperties. For example, using a combination of stretchable bands 202 aand hollow tubing 202 b, one can take advantage of the highercoefficient of friction provided by the bands for efficient spreading ofthe slit web or netting and the higher modulus of the hollow tubing toprevent excessive deflection as the slit web or netting at leastpartially wraps around a diverging disk apparatus such as that shown inFIG. 1A or 1B. In embodiments in which the slit web or polymeric nettingis run onto two different stretchable surfaces, the different types mayboth be provided in the same roller as shown in FIG. 1B. The slit web orpolymeric netting would sequentially contact both of the stretchablesurfaces during the 180 degrees of rotation in which the space betweenthe diverging disks is increasing. The ability to select more than onematerial is more straightforward when the stretchable surface comprisesbands, tubing, coiled springs, or a combination thereof than when thestretchable surface is a sleeve. Accordingly, in some embodiments inwhich the method is carried out on an apparatus including divergingdisks, the stretchable surface is not a sleeve attached to the twodiverging disks. Combinations of attachment methods of the stretchablesurface to the diverging disks such as clamps and pins may also beuseful.

As shown in FIGS. 1A and 1B, diverging disks 101 and 201 are positionedsuch that a portion of their peripheral surfaces have a closer spacingat one location d1 and a larger spacing at a second location d2. Theangle, which may be set by adapters such as 103, by the position ofshafts such as 205, by an angle in a shaft (not shown) or by acombination thereof, can be selected depending on the desired amount ofspread in the slit web or netting. For example, each diverging disk 101,201 may independently be angled at least 1, 2, 3, 4, or 5 degrees and upto 20, 15, or 10 degrees with respect to the machine direction of therunning web. In some embodiments, each diverging disk is independentlyangled in a range from 1 to 10 degrees or 2.5 to 7.5 degrees. Since thediverging disks may be independently angled, the method according to thepresent disclosure may be useful for spreading the slit web or nettinguniformly or non-uniformly with respect to the center of the slit web ornetting. In some embodiments, the strands closer to one edge of the slitweb or netting may be spread apart more than the strands closer to theopposite edge of the slit web or netting.

The difference between the spacing d2 and d1 is critical to the amountof spreading of the slit web or netting. This difference relates to theamount of spreading of the slit web or netting, and may equal themaximum amount of spreading assuming perfect traction between thestretching surface and the slit web or netting. In some embodiments, thespacing d2 is at least 25, 50, 60, 70, 80, 90, or 100 percent greaterthan the spacing d1. The percentage that the d2 spacing is greater thanthe d1 spacing can be determined, for example, by the formula[(d2−d1)/d1]*100. The closer the spacing of the diverging disks, themore spreading of the slit web or netting is allowed at a given angle ofthe diverging disks. Although other sizes may be useful, in someembodiments, d1 is at least 8 millimeters (mm) and up to 15.25centimeters (cm), 12.7 cm, or 12.1 cm. Also, the larger the divergingdisks, the more spreading of the slit web or netting is possible at agiven angle. As described in greater detail below, the method accordingto the present disclosure is useful, in some embodiments, for spreadingslit webs or nettings up to 10 cm in width, and it is possible toachieve an increase in width of at least 5, 15, 20, or 25 percent and upto 40, 50, 75, 100, 150, or 200 percent.

The increase in width of a slit web or netting that can be achieved inthe method disclosed herein is typically much greater than an increasein the width of a web observed when removing wrinkles. A person havingordinary skill in the art would understand that removing wrinkles from aweb typically only increases the width of the web by up to 2 percent.Therefore, it is unnecessary for a roller designed for removing wrinklesto have a spacing d2 that is at least 25, 50, 60, 70, 80, 90, or 100percent greater than the spacing d1. Furthermore, removing wrinkles istypically only necessary for webs of at least 30 cm wide.

A variety of diameters of the disks may be useful for the methoddisclosed herein. To achieve higher line speeds or a greater amount ofspreading, larger diameter disks having any of the angles or spacingsdescribed above may be useful. In some embodiments, the disks have adiameter of at least 10, 12, 14, or 16 cm.

While in some applications, it may be useful for the stretchable surfaceto be supported by a structure, for example, between the diverging disksthat prevents or minimizes the inward deflection of the stretchablesurface, such a support structure (e.g., a plurality of brushes) is nota requirement for the method disclosed herein. Accordingly, in someembodiments, the stretchable surface is not provided with a structure tosupport the stretchable surface opposite the side that contacts the slitweb or netting. For example, the stretchable surface in theseembodiments is not provided with a plurality of brushes that support thestretchable surface as it expands and retracts. In these embodiments,the stretchable surface is permitted to deflect inward as the slit webor netting contacts the stretchable surface. A certain amount ofdeflection will not hamper the spreading effect of the stretchablesurface.

The method according to the present disclosure does not require the useof diverging disks. In some embodiments, the stretchable surface can bestretched in the second direction by a conveyor belt apparatus 300 suchas that shown in FIG. 1C. Apparatus 300 includes a pair of divergingguides 311 for engaging and directing the side edges of the stretchablesurface 302. The diverging guides 311 can be used in combination withgripping or vacuum belts or clamps on the edges (not shown) of thestretchable surface. The guides 311 in combination with the stretchablesurface 302 form a continuous loop around a pair of pulleys 313. Inthese embodiments, the slit web or netting (not shown) can be broughtinto contact with the stretchable surface at narrower end 315. Themultiple strands of the slit web or netting can then be spread apart asit remains in contact with the stretchable surface and is moved to thewider end 317 and thereby stretched. In the illustrated embodiment,multiple bands 302 attached separately to the guides 311 provide thestretchable surface although this is not a requirement. In otherembodiments, the stretchable surface is provided by a continuous beltthat alternatively stretches and retracts. Any of the stretchablesurfaces and materials described above may be useful to providestretchable surface 302. Also, the conveyor belt apparatus can includeat least two different types of stretchable surfaces, as described abovein connection with the diverging disks. In some embodiments, a pair ofconveyor apparatuses 300 can be used together with the slit web ornetting directed between them. The sandwich configuration may help theslit web or netting to remain in contact with the stretching surfaces.

In the embodiment shown in FIG. 1C, like in the embodiments that includediverging disks (e.g., those shown in FIGS. 1A and 1B), each guide 311may independently be angled at least 1, 2, 3, 4, or 5 degrees and up to20, 15, or 10 degrees with respect to the machine direction of therunning web. In some embodiments, each guide 311 is independently angledin a range from 1 to 10 degrees or 2.5 to 7.5 degrees. Also, similar tothe embodiments that include diverging disks, the stretchable surface302 in FIG. 1C is not provided with a support structure to prevent thedeflection of the stretchable surface when it contacts the slit web ornetting. In some embodiments, the width of the apparatus at the widerend 317 is at least 25, 50, 60, 70, 80, 90, or 100 percent greater thanthe width of the apparatus at the narrower end 315. Similarly, for anyapparatus useful for carrying out the present disclosure, thestretchable surface is stretched at least 25, 50, 60, 70, 80, 90, or 100percent, for example, while it is in contact with the slit web orpolymeric netting.

Slit webs and nets that can be separated or spread according to themethods disclosed herein typically develop little to no stress in thedirection of stretching at least upon initially straining the slit webor netting the stretching direction. In some embodiments, the stretchingdirection is the second direction, transverse to the direction of theslits. In a slit web, the slits provide regions where any means fortransmission of force in the second direction is substantially absent.In a netting, the openings in the netting or spaces between strandsprovide regions where any means for transmission of force in thestretching direction is substantially absent. Accordingly, in someembodiments, the material to be spread on the stretchable surface has atensile modulus (i.e., the initial slope of the stress-strain curve) inthe first direction of at least 2, 3, 5, 10, 20, 50, or 100 times thetensile modulus of the material in the second direction. The tensilemodulus in the second direction can be affected by the size of the slitsin a slit web, as described in further detail below.

In some embodiments, at least some of the multiple strands of the slitweb are fully slit apart. In other words, these multiple strands arediscrete strands, not attached to each other, that may be formed byslitting continuously through the web in the machine direction. In theseembodiments, the slit web develops no stress in the second direction,which is transverse to the direction of the slits, upon separating thestrands of the slit web. In embodiments in which the slit web comprisesmechanical fastening elements on at least one major surface, for examplemale fastening elements having upstanding posts with bases attached tothe slit web, spreading the slit web using the method according to thepresent disclosure can provide a fastening assembly in which discretestrands of the slit web are attached to an adhesive layer through theirsecond major surfaces (i.e., opposite the first major surfaces havingthe upstanding posts) in a parallel fashion at a distance in thecross-direction from each other such that an alternating sequence ofmultiple parallel strips of exposed adhesive layer and of the mechanicalfastening strands is obtained. Such an assembly is described in U.S.Pat. Appl. Pub. No. 2007/0039142 (Petersen et al.). Separated multiplestrands of mechanical fastening elements may be useful in fastening tabseven when no exposed adhesive is present. See, e.g., Int. Pat. Appl.Pub. No. WO2011/163020 (Hauschildt et al.).

In other embodiments, portions of the multiple strands are attached toeach other. Various embodiments of the slit web in which the multiplestrands are attached to each other at intact bridging regions of webbefore and after they are spread are illustrated in FIGS. 2A through 2C,3A, 3B, 4A, and 4B and described below.

FIG. 2A illustrates an example of a portion of a slit web 10 a withinterrupted slits 20 that is spread in some embodiments of the methoddisclosed herein. In the illustrated embodiment, the slit web 10 aincludes mechanical fastening elements, which are male fasteningelements 12. Illustrated slit web 10 a has a thermoplastic backing 14with multiple rows 16 of male fastening elements 12 projecting from afirst surface of the backing 14. The first surface of the backing is thesurface that is visible in FIG. 2A. The first surface (that is, thesurface with mechanical fastening elements) can also be called the firstmajor surface in any of the embodiments disclosed herein. In theillustrated embodiment, the multiple rows 16 of male fastening elements12 are aligned in the MD although this is not a requirement. The term“row” refers to male fastening elements lined up in a particulardirection. The row or line of male fastening elements may besubstantially straight.

In the portion of slit web 10 a, interrupted slits 20 are cut into thebacking between some pairs of adjacent rows 16 of male fasteningelements 12. When an interrupted slit is cut between adjacent rows ofmale fastening elements 12, it typically means that the particular slitdoes not cross over a row of male fastening elements 12. The illustratedinterrupted slits 20 are linear in the same direction as the multiplerows 16, which in the illustrated embodiment is the MD, and extend fromthe top edge 18 to the bottom edge 28 of the backing 14. The interruptedslits are interrupted by intact bridging regions 22 of the backing 14.The bridging regions 22 are regions where the web is not cut through,and at least a portion of the bridging regions 22 can be consideredcollinear with interrupted slit 20. The intact bridging regions 22divide the interrupted slits into a series of spaced apart slit portions20 a. The spaced apart slit portions 20 a and 20 b and consequentlybridging regions 22 a and 22 b of adjacent interrupted slits arestaggered in a direction “CD” perpendicular to the direction “MD” of theinterrupted slits 20. The bridging regions are staggered such thatbridging region 22 b is located substantially midway between bridgingregions 22 a in the direction “MD”. However, in some embodiments, theupstanding posts 12, interrupted slits 20, and bridging regions 22, 22a, and 22 b may be positioned in other arrangements. When the slitportions and bridging regions are staggered, the number of bridgingregions necessary to make the slit mechanical fastener handle as anintegral unit can be minimized.

The slits of the plurality of slits, which may be interrupted slits 20as shown in FIG. 2A or complete slits, extend in a first direction thatis non-parallel to the CD. In some embodiments of the method disclosedherein, the slits extend in the MD. When it is said that a slit“extends” in a certain direction, it is meant that the slit is arrangedor aligned in that direction or at least predominantly in thatdirection. The slit may be linear. As used herein a “linear” slit can bedefined by two points in a line on the web. The slit may also besubstantially linear, which means that the slit can have a slightcurvature or slight oscillation. Some oscillation or curvature mayresult, for example, from the process of slitting a continuous web aswould be understood by a person skilled in the art. In some embodimentsof mechanical fasteners with male fastening elements made according tothe method of the present disclosure, any oscillation or curvature issuch that the slit generally does not have a portion that crosses over aMD-aligned row of male fastening elements. The slits may also benon-linear. For example, they may have a wavy or sawtooth pattern with asmall amplitude relative to the width of the web, and such a slit wouldalso be considered to extend in predominantly in a certain direction.

Referring again to FIG. 2A, the particular arrangement of the bridgingregions 22, 22 a, and 22 b can be designed, for example, based on thedesired length of the slits and the amount of spreading desired for themultiple strands 26. Various lengths of bridging regions 22, 22 a, and22 b may be useful. In some embodiments, any bridging regions 22 in agiven interrupted slit 20 have a combined length in the direction of theinterrupted slit of up to 50 (in some embodiments, 40, 30, 25, 20, 15,or 10) percent of the length of the slit web in the MD. In someembodiments, for maximizing the ability of the slit web 10 a to spread,it may be desirable to minimize the combined length of the bridgingregions in the direction of the interrupted slit. Minimizing thecombined length of the bridging regions 22 in the direction of theinterrupted slit may be accomplished by at least one of minimizing thelength of any particular bridging region 22 or maximizing the distancebetween bridging regions 22. In some embodiments, the length of onebridging region in the direction of the interrupted slit is up to 3, 2,or 1.5 mm and at least 0.25, 0.5, or 0.75 mm. In some embodiments, thenumber of bridging regions along the length of the slit web 10 a in thedirection of the interrupted slit is up to 1.5, 1.25, 1.0, 0.75, 0.60,or 0.5 per cm. The distance between bridging regions 22 in the directionof the interrupted slit may be, for example, at least 0.75, 1.0, 1.25,1.5, or 1.75 cm. Furthermore, the length of the interrupted slitportions between bridging regions can be adjusted and may be selected tomaximize the distance between bridging regions. In some embodiments, thelength of the slit portions 20 a, 20 b is at least 8 (in someembodiments, at least 10, 12, 14, 15, 16, 17, 18, 19, or 20) mm. In someembodiments, a ratio of a length of the slit portions to a width of oneof the multiple strands is at least 2 to 1 (in some embodiments, atleast 3:1, 5:1, 10:1, 12.5:1, or 15:1). In slit webs in which a ratio ofa length of the slit portions to the width of the multiple strands isless than 2:1, the tensile stress developed in the second direction maybecome too high to allow the slit web to spread in the second directionon the stretching surface. Typically, the interrupted slits of the slitwebs 10 a useful for practicing some embodiments of the presentdisclosure have longer slit regions and shorter bridging regions thanperforations that are designed to allow easy separation of two parts ofa film.

In some embodiments, slit portions 20 a, 20 b have a regular patternthat repeats down the slit web 10 a. In some embodiments, spacing (e.g.,in the MD or other direction of the interrupted slits) between slitportions 20 a may be uniform or substantially uniform (that is, thespacing may differ by up to 2 percent, 1 percent, or less than 1 or 0.5percent) although this is not a requirement.

For any of the embodiments of the method disclosed herein, the number ofslits (e.g., interrupted or complete slits) may be adjusted depending onthe desired product. The slits may be evenly spaced or unevenly spacedas desired. In some embodiments, there are up to 10, 9, 8, 7, 6, 5, 4,3, 2, or 1 slits per 10 mm across the width of the slit web in the CD.In some embodiments, changing the number of slits across the slit webmay be related to the number of rows of male fastening elements betweenany two adjacent slits, depending on the density of the male fasteningelements on the web. The number of rows of male fastening elementsbetween any two adjacent slits may be adjusted depending on therequirements of the application. In some embodiments, there are up to10, 9, 8, 7, 6, 5, 4, 3, 2 rows, or 1 row of male fastening elementsbetween any two adjacent slits. Typically, the width dimension of eachof the multiple strands formed between slits is wider than at least thebases of the upstanding posts of the male fastening elements. In someembodiments, there is a slit between every row or every other row ofmale fastening elements. In the embodiment illustrated in FIG. 2A, theinterrupted slits 20 are evenly spaced among the rows of male fasteningelements 12 although this is not a requirement. For multiple rows 16 ofmale fastening elements 12 that are evenly spaced, as illustrated, thespacing (e.g., distance in the CD in the illustrated embodiment) betweenmultiple rows 16 may differ by up to 10, 5, 2.5, or 1 percent. Likewise,for slits that are evenly spaced, the spacing (e.g., distance in the CD)between the slits may differ by up to 10, 5, 2.5, or 1 percent.

FIGS. 2B and 2C illustrate the effect of spreading the slit web likethat shown in FIG. 2A to different extents. When the slit web 10 b isspread in the second direction, shown with the arrows, multiple strands26 of the web are provided, which are attached to each other at least atsome of the intact bridging regions and separated from each otherbetween at least some of the intact bridging regions. In the illustratedembodiment, the separation between at least some of the multiple strandscreates openings 24. The method according to the present disclosuretypically increases the width of the slit web (that is, the dimension inthe CD).

FIG. 2C illustrates a greater amount of spreading than FIG. 2B. Asdescribed above in conjunction with FIG. 1A, the amount of spreadingprovided in the method disclosed herein can be controlled by a varietyof factors including the angle of the diverging disks relative to theaxis of the non-rotating shaft, and distance d2 relative to distance d1.In some embodiments, spreading the slit web is carried out by feedingthe slit web onto a stretchable surface multiple times in a series,which can also affect the extent of spreading. In some embodiments, thewidth of the spread web is at least 5, 10, 15, 20, or 25 percent greaterthan the width of the input slit web, which may include interrupted orcomplete slits. In some embodiments, the width of the spread web is upto 40, 50, 75, 100, 150, or 200 percent greater than the width of theinput slit web. In embodiments in which the multiple strands are notattached, the width of the spread web is the distance between theoutside edges of the outermost strands.

In the embodiment illustrated in FIG. 2C, at least two strands 26 a,including at least two rows of male fastening elements on each edge ofthe mechanical fastener, are not separated. A spread mechanicalfastening web having strands on the edge that are not spread apart maybe advantageous in some embodiments, for example, to provide areticulated mechanical fastening strip or patch with a straight edge.

While FIGS. 2A through 2C illustrate a backing 14 with male fasteningelements 12 that comprise upstanding posts, it should be understood thatother types of webs can be slit to provide slit web 10 a and spreadusing the method disclosed herein in the same manner to the same extentas spread mechanical fastening webs 10 b and 10 c. In some embodiments,the slit web can be a web of loop material or another fibrous web. Insome embodiments, the slit web can be a thermoplastic film withoutsurface structures. The slit web may also be a foamed film. In someembodiments, the slit web is a multilayered film, for example, having athermoplastic film layer and at least one of a fibrous layer or a foamedlayer.

FIG. 3A illustrates an example of a slit web portion with interruptedslits 20 and having male fastening elements, which is similar to theportion of slit web 10 a shown in FIG. 2A. However, in the embodimentshown in FIG. 3A, slit portions 20 a have different lengths than slitportions 20 b of adjacent slits, which results in openings 24 a and 24 bhaving different sizes after the slit web is spread as shown in FIG. 3B.That is, openings 24 a are shorter in the MD than openings 24 b. Theslit portions of the smaller size 20 a and slit portions of the largersize 20 b each may be aligned with each other across the slit web asshown in FIG. 3A. Or in other embodiments, slits of the same size may beoffset relative to each other in a regular pattern. Furthermore,referring again to FIG. 2A, the length of the bridging regions 22 may bemade to vary within a strand 26 or between strands 26 as desired for aparticular application or appearance. Although FIGS. 3A and 3Billustrate mechanical fasteners with male fastening elements, the sameslitting pattern and spreading using the method disclosed herein can becarried out with other types of webs (e.g., films, foams, fibrous webs,loop materials, and multilayered constructions as described above).

FIG. 4A illustrates an example of a slit web with interrupted slits,which is similar to the slit web 10 a shown in FIG. 2A. However, in theembodiment shown in FIG. 4A, slit portions 20 e have different lengthsthan slit portions 20 f, which results in openings 24 c and 24 d havingdifferent sizes after the slit web is spread as shown in FIG. 4B. Incontrast to the embodiment shown in FIGS. 3A and 3B, which illustratesinterrupted slits with slit portions of different lengths in the MD andthe corresponding resulting openings, FIGS. 4A and 4B illustratepatterns of slit portions of different lengths in different zones in theCD of the slit web. The multiple strands 26 c and 26 d have a differentappearance from each other in the same spread web, for example, multiplestrands 26 c and 26 d zig-zag or undulate with a different wavelengthand amplitude. The slit web and the slit-and-spread web shown in FIGS.4A and 4B, respectively, may or may not include male or femalemechanical fastening elements (not shown). Or the slit web and theslit-and-spread web shown in FIGS. 4A and 4B, respectively, may be anunstructured film, a fibrous web, a foamed material, or a multilayeredmaterial.

For any of the embodiments of the method of spreading a slit web havinginterrupted slits disclosed herein, the openings formed by theseparation of the multiple strands between at least some of the bridgingregions are in the form of a repeating pattern of geometric shapes. Inthe illustrated embodiments, the geometric shapes are polygons, whichmay be quadrilaterals such as rhombuses. In some embodiments of thespread web, including the embodiment illustrated in FIG. 2C, themultiple strands of the web attached to each other at least at some ofthe intact bridging regions form an angle β of less than 90 degrees, insome embodiments, less than 60 degrees, 45 degrees, or 20 degrees, andin some embodiments, in a range from 0.5 to 20 degrees. For example, insome embodiments, when a slit web having 19 mm slit portions 20 a isspread so that the width of the spread mechanical fastening web is 100%greater than the input slit web, the angle β is typically in a rangefrom about 5 to 10 degrees. In some embodiments, curved lines may beused, which can result in crescent shaped openings after spreading. Asshown in FIG. 4B, there may be more than one repeating pattern ofgeometric shaped openings. The openings may be evenly spaced or unevenlyspaced as desired. For openings that are evenly spaced, the spacing(e.g., distance in the CD) between the openings may differ by up to 10,5, 2.5, or 1 percent.

Although the methods of spreading a web illustrated in FIGS. 2A through2C, 3A and 3B, and 4A and 4B each show interrupted slits extendingparallel to the MD of the slit web, slits (e.g., interrupted or completeslits) may be made in any desired direction not parallel to the CD. Forexample, slits may be made at an angle from 1 to 85 degrees to the MD ofthe slit web. In some embodiments, slits are made at an angle in a rangefrom 35 to 55 degrees (e.g., 45 degrees) to the MD of the slit web.

The method according to the present disclosure may be useful for anywidth of the slit web in the CD. For example, the slit web may have awidth in the CD in a range from 5 mm to 10 cm, 1 cm to 5 cm, or 1 cm to3 cm wide. Also, the stretchable surface using for any of theembodiments of the method described herein may have an initial widthbefore stretching in a range from 8 mm to 15.25 cm, 1 cm to 15.25 cm, 1cm to 12.7 cm, 8 mm to 12.1 cm, or 1 cm to 10 cm wide although otherwidths may be useful.

The method of the present disclosure may be useful not only forseparating the strands of a slit web on a stretchable surface asdescribed above in connection with FIGS. 2A, 2B, 2C, 3A, 3B, 4A, and 4Bbut also for increasing the width of a polymeric netting. The method ofincreasing a width of a polymeric netting includes providing a polymericnetting having a length in a machine direction and running the polymericnetting in the machine direction onto a stretchable surface, wherein thepolymeric netting is in contact with the stretchable surface for a pathlength in the machine direction, wherein for at least a portion of thepath length, the stretchable surface is stretching in the cross-machinedirection, and wherein traction between the polymeric netting and thestretchable surface during stretching increases the width of at least aportion of the polymeric netting in the cross-machine direction. In someembodiments, the polymeric netting is formed after at least some of themultiple strands of the slit web described above in any of itsembodiments are at least partially separated. In these embodiments, themethod of increasing a width of a polymeric netting may be understood asa method of separating strands of a slit web further comprising runningthe slit web in the machine direction a second time onto a secondstretchable surface, wherein at least a portion of at least some of themultiple strands of the slit web are further separated on the secondstretchable surface. In some of these embodiments (e.g., any of theembodiments described above in which the stretchable surface connectedto two diverging disks), the method of increasing a width of a polymericnetting may be understood as a method of separating strands of a slitweb with bridging regions further comprising running the slit over asecond roller comprising two rotating diverging disks that are laterallyspaced and have a stretchable surface between them that stretches in thecross-machine direction for a portion of a rotation of the two rotatingdiverging disks, wherein at least a portion of at least some of themultiple strands of the slit web are further separated on the secondroller. However, in the method of increasing a width of a polymericnetting, the netting need not be formed from a slit web. The polymericnetting may be any netting in which any tensile stress that develops inthe cross-direction is low enough to allow the widening of the openingsof the netting when it is in contact with the stretchable surface.Although many polymeric nettings may be widened using this method, insome embodiments, the netting comprises an array of polymeric strandsperiodically joined together at bond regions throughout the array, butthe polymeric strands do not substantially cross over each other. Insome embodiments of these nettings at least 50 (at least 55, 60, 65, 70,75, 80, 85, 90, 95, 99, or even 100) percent by number of the polymericstrands do not cross over each other. In some embodiments of thesenettings, the netting has a thickness up to 750 micrometers (in someembodiments, up to 500 micrometers, 250 micrometers, 100 micrometers, 75micrometers, 50 micrometers, or even up to 25 micrometers; in a rangefrom 10 micrometers to 750 micrometers, 10 micrometers to 750micrometers, 10 micrometers to 500 micrometers, 10 micrometers to 250micrometers, 10 micrometers to 100 micrometers, 10 micrometers to 75micrometers, 10 micrometers to 50 micrometers, or even 10 micrometers to25 micrometers). In some embodiments of these nettings, at least some ofthe polymeric strands have a core including a first polymericcomposition and a sheath comprising a second, different polymericcomposition. Examples of useful netting are described in Int. Pat. Appl.Pub. Nos. WO 2013/028654 (Ausen et al.) and WO 2013/032683 (Ausen etal.), the disclosures of which are incorporated herein by reference intheir entirety. Nettings that may be widened according to the methoddisclosed herein may be useful, for example, in wound care applications,surgical drapes, and absorbent articles. In some of these embodiments,at least a portion of the netting is made from an elastic polymericcomposition. Polymeric nettings that include mechanical fasteningelements, such as those described in co-pending U.S. patent applicationSer. No. 13/587,655, filed Aug. 16, 2012, and incorporated by referencein its entirety herein, may also be suitable for processing with themethod disclosed herein.

In some embodiments, the slit web useful in the method disclosed hereinor the resulting spread web is made of a thermoplastic material.Suitable thermoplastic materials include polyolefin homopolymers such aspolyethylene and polypropylene, copolymers of ethylene, propylene and/orbutylene; copolymers containing ethylene such as ethylene vinyl acetateand ethylene acrylic acid; polyesters such as poly(ethyleneterephthalate), polyethylene butyrate and polyethylene napthalate;polyamides such as poly(hexamethylene adipamide); polyurethanes;polycarbonates; poly(vinyl alcohol); ketones such aspolyetheretherketone; polyphenylene sulfide; and mixtures thereof.Typically, in embodiments in which the slit web includes male fasteningelements, the thermoplastic is a polyolefin (e.g., polyethylene,polypropylene, polybutylene, ethylene copolymers, propylene copolymers,butylene copolymers, and copolymers and blends of these materials).

In the embodiments of the slit web useful in the method disclosed hereinor the resulting spread web that includes male fastening elements, thebacking and the male fastening elements are typically integral (that is,formed at the same time as a unit, unitary). Upstanding posts on abacking can be made, for example, by feeding a thermoplastic materialonto a continuously moving mold surface with cavities having the inverseshape of the posts. The thermoplastic material can be passed between anip formed by two rolls or a nip between a die face and roll surface,with at least one of the rolls having the cavities. The cavities may bein the inverse shape of a capped post having a loop-engaging head or maybe in the inverse shape of an upstanding post without loop-engagingheads (e.g., a precursor to a male fastening element). Pressure providedby the nip forces the resin into the cavities. In some embodiments, avacuum can be used to evacuate the cavities for easier filling of thecavities. The nip typically has a large enough gap such that a coherentbacking is formed over the cavities. The mold surface and cavities canoptionally be air or water cooled before stripping the integrally formedbacking and upstanding hook elements from the mold surface such as by astripper roll. If the posts formed upon exiting the cavities do not haveloop-engaging heads, loop-engaging heads could be subsequently formedinto hooks by a capping method as described in U.S. Pat. No. 5,077,870(Melbye et al.). Typically, the capping method includes deforming thetip portions of the hook elements using heat and/or pressure. The heatand pressure, if both are used, could be applied sequentially orsimultaneously.

Suitable tool rolls include those formed from a series of platesdefining a plurality of post-forming cavities about its periphery suchas those described, for example, in U.S. Pat. No. 4,775,310 (Fischer).Cavities may be formed in the plates by drilling or photoresisttechnology, for example. Other suitable tool rolls may includewire-wrapped rolls, which are disclosed along with their method ofmanufacturing, for example, in U.S. Pat. No. 6,190,594 (Gorman et al.).Another example of a method for forming a thermoplastic backing withupstanding posts includes using a flexible mold belt defining an arrayof upstanding post-shaped cavities as described in U.S. Pat. No.7,214,334 (Jens et al.). Yet other useful methods for forming athermoplastic backing with upstanding posts can be found in U.S. Pat.No. 6,287,665 (Hammer), U.S. Pat. No. 7,198,743 (Tuma), and U.S. Pat.No. 6,627,133 (Tuma).

The male fastening elements in the slit web or spread mechanicalfastening web disclosed herein may have loop-engaging heads that have anoverhang or may be upstanding posts having distal tips that can beformed into loop-engaging heads, if desired. The term “loop-engaging” asused herein relates to the ability of a male fastening element to bemechanically attached to a loop material. Generally, male fasteningelements with loop-engaging heads have a head shape that is differentfrom the shape of the post. For example, the male fastening element maybe in the shape of a mushroom (e.g., with a circular or oval headenlarged with respect to the stem), a hook, a palm-tree, a nail, a T, ora J. The loop-engageability of male fastening elements may be determinedand defined by using standard woven, nonwoven, or knit materials. Aregion of male fastening elements with loop-engaging heads generallywill provide, in combination with a loop material, at least one of ahigher peel strength, higher dynamic shear strength, or higher dynamicfriction than a region of posts without loop-engaging heads. Malefastening elements that have “loop-engaging overhangs” or “loop-engagingheads” do not include ribs that are precursors to fastening elements(e.g., elongate ribs that are profile extruded and subsequently cut toform male fastening elements upon stretching in the direction of theribs). Such ribs would not be able to engage loops before they are cutand stretched. Such ribs would also not be considered upstanding posts.Typically, male fastening elements that have loop-engaging heads have amaximum thickness dimension (in either dimension normal to the height)of up to about 1 (in some embodiments, 0.9, 0.8, 0.7, 0.6, 0.5, or 0.45)millimeter. In some embodiments, the male fastening elements have amaximum height (above the backing) of up to 3 mm, 1.5 mm, 1 mm, or 0.5mm and, in some embodiments a minimum height of at least 0.05 mm, 0.1mm, or 0.2 mm. In some embodiments, the upstanding posts have aspectratio (that is, a ratio of height to width at the widest point) of atleast about 2:1, 3:1, or 4:1.

In some embodiments of a slit web having male fastening elements usefulfor practicing the present disclosure, at least a portion of eachloop-engaging overhang (e.g., at the cap or head) extends at a nonzeroangle to the direction of the slits. In some embodiments, each malefastening element has a cap with loop engaging overhangs extending inmultiple (i.e., at least two) directions. For example, the upstandingpost may be in the shape of a mushroom, a nail, a palm tree, or a T. Insome embodiments, the upstanding posts are provided with a mushroom head(e.g., with an oval or round cap distal from the thermoplastic backing).In other embodiments, loop-engaging overhangs (e.g., at the cap or head)on the upstanding posts of the slit web extend parallel to the MD. Forexample, the upstanding posts may have the shape of a J (e.g., as shownin U.S. Pat. No. 5,953,797 (Provost et al.).

In spread mechanical fastening web 10 b and 10 c illustrated in FIGS. 2Band 2C, the male fastening elements 12 on a first strand 26 are arrangedin a series 16 a that is non-parallel to a series 16 b of male fasteningelements 12 on a second, adjacent strand 26. The series 16 a and 16 b ofmultiple upstanding posts and the multiple strands themselves from whichthey project can undulate or zig-zag along the length of the spreadmechanical fastening web 10 b or 10 c, for example, from the top edge 18to the bottom edge 28. In the illustrated embodiment, the caps visibleon the upstanding posts of the male fastening elements 12 have an ovalshape, and these caps are oriented in different directions along themultiple strands 26 in the MD. When the caps are circular in shape, itmay not be observed that the caps are oriented in different directionsalong the multiple strands 26, unless the cap is marked in some way. Inthe illustrated embodiment, the caps on a first strand 26 are orientedin a different direction than the caps on a second, adjacent strand 26.In embodiments in which slit web 10 a includes male fastening elementshaving loop-engaging overhangs aligned only parallel to the MD,spreading the slit web 10 a typically results in the loop-engagingoverhangs oriented in different directions along the multiple strands inthe MD as shown in FIG. 2C. When loop-engaging overhangs are oriented inmultiple directions (e.g., not only one direction such as the machinedirection), enhanced engagement of a loop material may advantageouslyresult.

Loop materials useful for practicing some embodiments of the presentdisclosure (e.g., when the web is a loop material) can be any suitablematerial that interlocks with corresponding hook fastening elements. Insome embodiments, the loop fastening elements are typically formed fromknitted fabrics, woven fabrics, or non-woven fabrics. The term“non-woven” refers to a material having a structure of individual fibersor threads that are interlaid but not in an identifiable manner such asin a knitted fabric. Examples of non-woven webs include spunbond webs,spunlaced webs, airlaid webs, meltblown web, and bonded carded webs. Thespread web prepared by the method disclosed herein may include fiberloops projecting from a knitted, woven, or non-woven backing or may beextrusion-bonded, adhesive-bonded, and/or sonically-bonded fiber loops.Useful loop materials may be made of natural fibers (e.g., wood orcotton fibers), synthetic fibers (e.g., thermoplastic fibers), or acombination of natural and synthetic fibers. Examples of suitablematerials for forming thermoplastic fibers include polyolefins (e.g.,polyethylene, polypropylene, polybutylene, ethylene copolymers,propylene copolymers, butylene copolymers, and copolymers and blends ofthese polymers), polyesters, and polyamides. The fibers may also bemulti-component fibers, for example, having a core of one thermoplasticmaterial and a sheath of another thermoplastic material.

In some embodiments, the web of loop material that can be spreadaccording to the method disclosed herein comprises a fibrous layerdisposed on a backing. Suitable backings include textiles, paper,thermoplastic films (e.g., single- or multilayered films, coextrudedfilms, laterally laminated films, or films comprising foam layers), andcombinations thereof. For thermoplastic backings, the thermoplastic canbe any of those described above in connection with a thermoplasticbacking having male fastening elements. Examples of suitable loopmaterials are described, for example, in U.S. Pat. No. 5,256,231 (Gormanet al.) and U.S. Pat. No. 5,389,416 (Mody et al.). As described in U.S.Pat. No. 5,256,231 (Gorman et al.), the fibrous layer in a loop materialaccording to some embodiments can comprise arcuate portions projectingin the same direction from spaced anchor portions on the backing.

The method according to the present disclosure can be useful with slitwebs or nets having a variety of thicknesses. In some embodiments, thethickness of the slit web that may be spread according to the methoddescribed herein may be up to about 400, 250, 150, 100, 75 or 50micrometers, depending on the desired application, which does notnecessarily include the height of male or female mechanical fasteningelements on the surface of the web. In some embodiments, the thicknessof the web is in a range from 30 to about 225 micrometers, from about 50to about 200 micrometers, or from about 100 to about 150 micrometers. Insome embodiments wherein the web is thermoplastic, the thermoplastic webhas stretch-induced molecular orientation, for example, when thethermoplastic web is stretched after formation of upstanding posts. Inother embodiments, the thermoplastic web is not provided withmacroscopic stretch-induced molecular orientation in the direction ofthe slits or in the direction of spreading. In embodiments in which themultiple strands of the spread web are attached to each other at intactbridging regions and separated from each other between the intactbridging regions, there may be some stress-induced orientation localizedin the bridging regions.

When separating strands of a web including interrupted slits, the methodof the present disclosure can typically spread a slit web whileadvantageously not allowing all of the attached multiple strands of thespread web to twist out-of-plane. Twisting out-of-plane can result whenspreading a slit web as shown in the photograph of FIG. 5. Pieces ofloop material were attached to the edges of a slit mechanical fastenerweb portion with male fastening elements such as that shown in FIG. 2A.When the pieces of loop material were pulled apart, the attached strandsof the slit web tended to twist out of the plane of the web as shown inFIG. 5. The amount of out-of-plane twisting is typically affected, forexample, by the extent to which the slit web is spread. Twisted strandsof the spread web create a non-uniform contact surface, which cancomplicate heat transfer to the web and complicate the use of a nip infurther web processing (e.g., annealing or laminating as describedbelow) since the twisted strands may be crushed by the nip.

A number of features of the method according to the present disclosurecan help control the tendency of the attached strands of the slit web totwist out-of-plane. The traction between the slit web and thestretchable surface can help to keep the attached strands from twistingout of plane. The tension applied in the machine direction that causesthe roller shown in FIG. 1A to exert a force on the slit web normal tothe slit web can also help to keep the attached strands in plane. Inthis way, the method disclosed herein may be considered to maintain orconstrain at least some of the multiple strands in an arrangementsubstantially coplanar with the plane of the web, for example, as theweb leaves the stretchable surface. A substantially “coplanar”arrangement refers to the strands occupying substantially the sameplane. The term “substantially” in this regard can mean that at leastsome of the multiple strands can be twisted out of plane by up to 15,10, or 5 degrees. The phrase “at least some” with regard to the multiplestrands being constrained refers to at least 25, 50, 75, or 90 percentor more of the multiple strands being constrained.

A number of web handling or web processing techniques may be useful in avariety of combinations for some embodiments of the method disclosedherein. For any of the aforementioned embodiments of the methodaccording to the present disclosure, providing a slit web can be carriedout in a variety of ways. For example, rotary die cutting of acontinuous web may be useful. Interrupted slits can be made, forexample, by using rotary cutting blades having gaps to form the bridgingregions. The height of the blade in the gaps may be adjusted to allowfor the bridging regions to be partially cut or not cut at all,depending on the desired embodiment. Other cutting methods (e.g., lasercutting) may also be useful. For embodiments in which the web includesmechanical fastening elements on at least one surface, cutting can beperformed from either surface of the continuous web. A slit may be cut“through” the web, which means that the slit cuts through the entirethickness of the web. In other embodiments, the slit may be apartial-depth slit as long as the stretching surface can pull apart thepartial depth slit. The partial-depth slit may penetrate, for example,80, 85, or 90 percent of the thickness of the web or more, which meansthe solution to the equation:(depth of the slit divided by the thickness of the web)×100is at least 80, 85, or 90 in some embodiments. Other methods of slittinga web can be found, for example, in U.S. Pat. Appl. Pub. No.2011/0313389 (Wood et al.).

When the slitting step comes immediately before feeding the slit webonto a stretching surface, the web can be guided before it is slit,which may be easier than guiding the slit web. This can be advantageousboth in embodiments in which the slit web is fully slit and inembodiments in which the multiple strands are joined at bridgingregions. In some embodiments, when male fastening elements are formed asdescribed above, for example, where a thermoplastic material is fed ontoa continuously moving mold surface with cavities having the inverseshape of upstanding posts, slitting the web and spreading the slit webaccording to the method disclosed herein can be carried out before orafter a capping step is carried out to form loop-engaging heads. Also,deforming the distal tip to form a cap can be carried out, for example,after slitting through the web but before spreading the slit web; afterspreading the slit web but before annealing (described below); or afterannealing as desired. The formation of male fastening elements can alsoinclude a step in which the shape of the cap is changed, for example, asdescribed in U.S. Pat. No. 6,132,660 (Kampfer). Such a cap modifyingstep can be carried out directly after capping or after any of theslitting, spreading, or further processing steps described herein.

In some embodiments, the method according to the present disclosurefurther comprises heating the spread web. In some embodiments, inparticular in embodiments in which the multiple strands are attached atintact bridging regions, the method according to the present disclosurefurther comprises annealing the spread web. In some embodiments,annealing comprises heating the spread web. In some embodiments,annealing comprises heating and then cooling (e.g., rapidly cooling) thespread web to maintain its configuration. Heating and/or annealing canbe carried out, for example, after the spread web has been spread to thefinal desired extent or at an intermediate stage, for example, if thespread web is spread a second time with a second stretchable surface.Annealing the spread web can be useful, for example, depending on theextent of spreading, and can be useful to maintain the openings betweenmultiple strands, for example, when the width of the slit web has beenincreased by at least 50 percent. Annealing can also be useful, forexample, for maintaining at least some of the multiple strands in asubstantially coplanar arrangement. In some embodiments, includingembodiments in which the web includes mechanical fastening elements,heating is only applied to the second surface of the spread mechanicalfastening web (i.e., the surface opposite the first surface from whichthe mechanical fastening elements project) to minimize any damage to themechanical fastening elements that may result from heating. In someembodiments, the stretchable surface is heated. In these embodiments,the slit web may be arranged so that any mechanical fastening elementsthat may be present face away from the stretchable surface. Heating mayalso be carried out on a continuous web, for example, using heatedrollers, for example, after the slit web is spread. Non-contact heatingmethods such as IR irradiation, hot air treatment, or by directing theweb through a heated chamber may also be useful, for example, when theslit web is arranged so that any mechanical fastening elements that maybe present face toward the stretchable surface. It may also be useful,in some embodiments, to heat the slit web before it is spread using anyof these heating methods.

In some embodiments, the slit web or netting is heated, for example, bynon-contact methods, while it is in contact with the stretchablesurface. In embodiments in which the stretchable surface is connected todiverging disks, for example, the slit web or netting may be heated forat least a portion of the rotation in which the stretchable surface isstretching. The slit web or netting may be cooled during the lastportion of the rotation or as it is removed from the stretchablesurface. In these and other embodiments, chilled air may be useful, forexample, to anneal the slit web as it is removed from the stretchablesurface.

A diagrammatical representation of an embodiment of an apparatus 1000for carrying out the method of the present disclosure is shown in FIG.6. In FIG. 6, slit web or netting 10 a is directed over roller 1050,which may be useful, for example, for adjusting the tension in the web10 a. Slit web 10 a is then spread by moving it over stretchable surfaceroller 1100 to provide spread web or netting 10 b. The stretchablesurface roller may be in accordance with FIG. 1A or other embodimentsdescribed above. Spread web or netting 10 b can optionally be handled byone or more other rollers 1150, which may be a rotating heated cylinder(or heated roller) as described above. In some embodiments, roller 1150may be a high-friction roller (e.g., comprising an elastomeric materialas described above or a material with a rough surface). Thehigh-friction roller may be heated or chilled, if desired, or may beuseful at room temperature. A high-friction roller may be useful, forexample, for holding the spread web in a spread configuration whether ornot the web is annealed. In some embodiments, a heated, high-frictionroller may be useful for annealing the spread web. In the illustratedembodiment, the spread web or netting 10 b is then moved over a secondstretchable surface roller 1200 where the web can be spread to a greaterextent. In the illustrated embodiment, the spread web is then laminatedto a carrier web 45 to form a laminate 40. In the illustratedembodiment, lamination is carried out in a nip formed by rollers 1500.In some embodiments, particularly embodiments in which the multiplestrands of the slit and spread web are attached at intact bridgingregions of the web, spread web can be directed onto a rotating heatedcylinder optionally followed by a rotating chilled cylinder to annealand rapidly cool the spread web before lamination.

In some embodiments, the slit web is coated with adhesive on its surfaceopposite the surface that contacts the stretchable surface. In some ofthese embodiments, mechanical fastening elements face toward thestretchable surface, and the adhesive coating faces away from thestretchable surface. In these embodiments, the non-contact heatingmethods described above may be useful. The spread mechanical fasteningweb could then come in contact with a chilled cylinder as describedabove before it is laminated to a carrier.

For any of the embodiments of the method of spreading a web disclosedherein in which the multiple strands of the spread web are attached atintact bridging regions of the web, the spread web may be in the form ofa roll. The bridging regions interrupting the interrupted slits allowthe spread web to be handled as an integral unit, for example, to behandled in roll form and converted as desired.

For any of the embodiments in which the slit web includes continuousslits and the multiple strands of the slit web are not attached to eachother, laminating the spread web to a carrier immediately after it isspread on the stretchable surface roller may be useful. In theseembodiments, positioning downstream roller 1150 and/or laminating roller1500 close to the stretchable surface roller 1100 may be useful tominimize the handling of the individual separated strands. Also,although the bridging regions in the embodiments of the spread web inwhich the multiple strands are attached at intact bridging regions allowit to be handled as an integral unit, it may be useful to laminate thespread web to a carrier (e.g., even a sacrificial carrier) for ease ofhandling, for fixing the multiple strands of the spread web in a spreadconfiguration to maintain the separation between the multiple strands,or for making a laminate for a selected application (e.g., a mechanicalfastening laminate). The spread web may be joined to a carrier, forexample, by lamination (e.g., extrusion lamination), adhesives (e.g.,pressure sensitive adhesives), or other bonding methods (e.g.,ultrasonic bonding, compression bonding, or surface bonding).

The carrier 45 may be continuous (i.e., without any through-penetratingholes) or discontinuous (e.g. comprising through-penetratingperforations or pores). The carrier may comprise a variety of suitablematerials including woven webs, non-woven webs (e.g., spunbond webs,spunlaced webs, airlaid webs, meltblown web, and bonded carded webs),textiles, plastic films (e.g., single- or multilayered films, coextrudedfilms, laterally laminated films, or films comprising foam layers), andcombinations thereof. In some embodiments, including embodiments inwhich the laminate is a mechanical fastening laminate, the carrier is afibrous material (e.g., a woven, nonwoven, or knit material). In someembodiments, the carrier comprises multiple layers of nonwoven materialswith, for example, at least one layer of a meltblown nonwoven and atleast one layer of a spunbonded nonwoven, or any other suitablecombination of nonwoven materials. For example, the carrier may be aspunbond-meltbond-spunbond, spunbond-spunbond, orspunbond-spunbond-spunbond multilayer material. Or, the carrier may be acomposite web comprising a nonwoven layer and a dense film layer.Fibrous materials that may provide useful carriers may be made from anyof the fibers described above as useful for making loop materials.Useful carriers may have any suitable basis weight or thickness that isdesired for a particular application. For a fibrous carrier, the basisweight may range, e.g., from at least about 5, 8, 10, 20, 30, or 40grams per square meter, up to about 400, 200, or 100 grams per squaremeter. The carrier may be up to about 5 mm, about 2 mm, or about 1 mm inthickness and/or at least about 0.1, about 0.2, or about 0.5 mm inthickness.

In some embodiments, the slit web is directed onto a high-frictionsurface after at least some of the multiple strands are at leastpartially separated. As described above, in some embodiments, thehigh-friction surface is a high-friction roller. In other embodiments,the high-friction surface is an adhesive tape (that is, an adhesivedisposed on a carrier). In these embodiments, the adhesive may be apressure-sensitive adhesive, and the carrier may be any of thosedescribed above. When the slit web is directed onto an adhesive tapesoon after at least some of the multiple strands are at least partiallyseparated, annealing may not be necessary since the adhesive can keepthe strands separated. In some embodiments, joining the slit web to theadhesive tape is not carried out in a nip as described above and shownin FIG. 6. Instead, in some embodiments, the laminate is nipped downwebfrom where the slit web is joined to the adhesive tape. This method mayhelp to keep the laminate flat.

In some embodiments where the spread web includes a thermoplasticbacking (e.g., with upstanding posts or a fibrous or foam layer thereon)the thermoplastic backing can be joined to a fibrous web carrier usingsurface bonding or loft-retaining bonding techniques. The term“surface-bonded” when referring to the bonding of fibrous materialsmeans that parts of fiber surfaces of at least portions of fibers aremelt-bonded to the second surface of the backing, in such a manner as tosubstantially preserve the original (pre-bonded) shape of the secondsurface of the backing, and to substantially preserve at least someportions of the second surface of the backing in an exposed condition,in the surface-bonded area. Quantitatively, surface-bonded fibers may bedistinguished from embedded fibers in that at least about 65% of thesurface area of the surface-bonded fiber is visible above the secondsurface of the backing in the bonded portion of the fiber. Inspectionfrom more than one angle may be necessary to visualize the entirety ofthe surface area of the fiber. The term “loft-retaining bond” whenreferring to the bonding of fibrous materials means a bonded fibrousmaterial comprises a loft that is at least 80% of the loft exhibited bythe material prior to, or in the absence of, the bonding process. Theloft of a fibrous material as used herein is the ratio of the totalvolume occupied by the web (including fibers as well as interstitialspaces of the material that are not occupied by fibers) to the volumeoccupied by the material of the fibers alone. If only a portion of afibrous web has the second surface of the backing bonded thereto, theretained loft can be easily ascertained by comparing the loft of thefibrous web in the bonded area to that of the web in an unbonded area.It may be convenient in some circumstances to compare the loft of thebonded web to that of a sample of the same web before being bonded, forexample, if the entirety of fibrous web has the second surface of thebacking bonded thereto. In some of these embodiments, the joiningcomprises impinging heated gaseous fluid (e.g., ambient air,dehumidified air, nitrogen, an inert gas, or other gas mixture) onto afirst surface of the fibrous web carrier while it is moving; impingingheated fluid onto the second surface of the backing while the continuousweb is moving, wherein the second surface is opposite the fibrous layer,loop, or upstanding posts the backing; and contacting the first surfaceof the fibrous web with the second surface of the backing so that thefirst surface of the fibrous web is melt-bonded (e.g., surface-bonded orbonded with a loft-retaining bond) to the second surface of the backing.Impinging heated gaseous fluid onto the first surface of the fibrous weband impinging heated gaseous fluid on the second surface of the backingmay be carried out sequentially or simultaneously. Further methods andapparatus for joining a continuous web to a fibrous carrier web usingheated gaseous fluid may be found in U.S. Pat. Appl. Pub. Nos.2011/0151171 (Biegler et al.) and 2011/0147475 (Biegler et al.).

In some embodiments wherein the spread web is joined to a carrier, oneor more zones of the carrier may comprise one or more elasticallyextensible materials extending in at least one direction when a force isapplied and returning to approximately their original dimension afterthe force is removed. However, in some embodiments, at least the portionof the carrier joined to the multiple strands of web is not stretchable.In some embodiments, the portion of carrier joined to the multiplestrands will have up to a 10 (in some embodiments, up to 9, 8, 7, 6, or5) percent elongation in the CD. In some embodiments, the carrier may beextensible but nonelastic. In other words, the carrier may have anelongation of at least 5, 10, 15, 20, 25, 30, 40, or 50 percent butsubstantially no recovery from the elongation (e.g., up to 10 or 5percent recovery). Suitable extensible carriers may include nonwovens(e.g., spunbond, spunbond meltblown spunbond, or carded nonwovens). Insome embodiments, the nonwoven may be a high elongation carded nonwoven(e.g., HEC). In some embodiments, the carrier is not pleated.

In some embodiments wherein the spread web is joined to a carrier, atleast one of the carrier or the spread web is provided with a layer ofadhesive. In some of these embodiments, the spread web is bonded to thecarrier with the adhesive to form a laminate, and the adhesive isexposed between the multiple strands in the laminate. This may beuseful, for example, when the web is a mechanical fastening web.

In some embodiments, the method according to the present disclosureincludes cutting the spread web in the CD. In embodiments in which thespread web includes mechanical fastening elements, such convertingprovides a spread mechanical fastening patch. Cutting the spread web canbe carried out, for example, after the spread mechanical fastening webis laminated to a carrier, and the patch can be considered a fasteninglaminate.

Fastening laminates made by the methods disclosed herein are useful, forexample, in absorbent articles. Absorbent articles may have at least afront waist region, a rear waist region, and a longitudinal center linebisecting the front waist region and the rear waist region, wherein atleast one of the front waist region or the rear waist region comprisesthe fastening laminate disclosed herein. The fastening laminate may bein the form of a fastening tab or landing zone that is bonded to atleast one of the front waist region or the rear waist region. Afastening tab may extend outwardly from at least one of the leftlongitudinal edge or the right longitudinal edge of the absorbentarticle. In other embodiments, the fastening laminate may be an integralear portion of the absorbent article. The carrier at the user's end of afastening tab may exceed the extension of the spread mechanicalfastening patch thereby providing a fingerlift. When the spreadmechanical fastening patch is used in a fastening tab, exposed adhesivethat may be present in some embodiments between the multiple strands ofthe spread mechanical fastening patch may be useful for “anti-flagging”or for maintaining the disposable absorbent article in a rolled up stateafter use. Also when the spread mechanical fastening patch is used as alanding zone or fastening tab, exposed adhesive that may be present insome embodiments between the multiple strands of the spread mechanicalfastening patch may be useful to provide a combination of mechanical andadhesive fastening. The fastening laminate made by the methods disclosedherein may also be useful, for example, for disposable articles such assanitary napkins. Mechanical fasteners and laminates made according tothe present disclosure may also be useful in many other fasteningapplications, for example, assembly of automotive parts or any otherapplication in which releasable attachment may be desirable.

Some Embodiments of the Disclosure

In a first embodiment, the present disclosure provides a method ofseparating strands of a slit web, the method comprising:

providing a slit web having a length in a machine direction, wherein theslit web comprises multiple strands provided by a plurality of slitsextending in a first direction not parallel to a cross-machinedirection; and

running the slit web in the machine direction onto a stretchablesurface, wherein the slit web is in contact with the stretchable surfacefor a path length in the machine direction, wherein for at least aportion of the path length, the stretchable surface is stretching in thecross-machine direction, and wherein traction between the slit web andthe stretchable surface during stretching at least partially separatesat least some of the multiple strands of the slit web in a seconddirection transverse to the first direction.

In a second embodiment, the present disclosure provides the method ofthe first embodiment, wherein the slit web has a width after contactingthe stretchable surface that is at least five percent greater than itswidth before it contacts the stretchable surface.

In a third embodiment, the present disclosure the method of the first orsecond embodiment, wherein the slit web comprises mechanical fasteningelements on at least one major surface.

In a fourth embodiment, the present disclosure provides the method ofthe third embodiment, wherein the slit web comprises loops.

In a fifth embodiment, the present disclosure provides the method of thethird embodiment, wherein the mechanical fastening elements are malefastening elements comprising upstanding posts having bases attached tothe slit web.

In a sixth embodiment, the present disclosure provides the method of thefifth embodiment, further comprising providing a thermoplastic backinghaving multiple rows of the upstanding posts, wherein providing the slitweb comprises slitting through the web between at least some pairs ofadjacent rows of the upstanding posts.

In a seventh embodiment, the present disclosure provides the method ofthe fifth or sixth embodiment, wherein the male fastening elementsfurther comprise caps distal from the slit web.

In an eighth embodiment, the present disclosure provides the method ofthe seventh embodiment, wherein the caps have loop-engaging overhangsextending beyond the upstanding posts at a non-zero angle to thedirection of the interrupted slits.

In a ninth embodiment, the present disclosure provides the method of anyone of the third to eighth embodiments, wherein the slit web is arrangedso that the mechanical fastening elements face away from the stretchablesurface.

In a tenth embodiment, the present disclosure provides the method of anyone of the third to eighth embodiments, wherein the slit web is arrangedso that the mechanical fastening elements face toward the stretchablesurface.

In an eleventh embodiment, the present disclosure provides the method ofthe tenth embodiment, wherein the slit web is coated with adhesive onits surface opposite the mechanical fastening elements.

In a twelfth embodiment, the present disclosure provides the method ofany one of the first to eleventh embodiments, wherein the stretchablesurface does not have a support surface contacting the stretchablesurface on a side opposite a side of the stretchable surface thatcontacts the slit web.

In a thirteenth embodiment, the present disclosure provides the methodof any one of the first to twelfth embodiments, wherein at least some ofthe multiple strands of the slit web are not attached to each other.

In a fourteenth embodiment, the present disclosure provides the methodof any one of the first to twelfth embodiments, wherein the plurality ofslits are interrupted by intact bridging regions of the web, wherein forat least some adjacent interrupted slits, the intact bridging regionsare staggered in a direction transverse to the first direction, andwherein the stretching provides a spread web comprising multiple strandsof the slit web attached to each other at least at some of the intactbridging regions and separated from each other between at least some ofthe intact bridging regions.

In a fifteenth embodiment, the present disclosure provides the method ofthe fourteenth embodiment, wherein the intact bridging regions dividethe interrupted slits into a series of slit portions aligned in thefirst direction, and wherein a ratio of a length of the slit portions toa width of one of the multiple strands is at least 2 to 1.

In a sixteenth embodiment, the present disclosure provides the method ofthe fourteenth or fifteenth embodiment, wherein the multiple strands ofthe slit web attached to each other at least at some of the intactbridging regions form an angle of less than 90 degrees.

In a seventeenth embodiment, the present disclosure provides the methodof any one of the first to sixteenth embodiments, wherein stretchablesurface comprises an elastomer.

In an eighteenth embodiment, the present disclosure provides the methodof any one of the first to seventeenth embodiments, wherein thestretchable surface is provided by at least one stretchable band,stretchable tubing, at least one coiled spring, or a combinationthereof.

In a nineteenth embodiment, the present disclosure provides the methodof any one of the first to eighteenth embodiments, wherein the slit webis run onto at least two different stretchable surfaces.

In a twentieth embodiment, the present disclosure provides the method ofany one of the first to nineteenth embodiments, wherein running the slitweb in the machine direction comprises running the slit web onto aroller comprising two rotating diverging disks that are laterally spacedand have the stretchable surface between them that stretches in thecross-machine direction for a portion of a rotation of the two rotatingdiverging disks.

In a twenty-first embodiment, the present disclosure provides the methodof the twentieth embodiment, wherein at least one diverging disk has anangle to the machine direction of at least one degree.

In a twenty-second embodiment, the present disclosure provides themethod of the twentieth or twenty-first embodiment, wherein there aremultiple stretchable bands, stretchable tubing, multiple coiled springs,or a combination thereof attached to the diverging disks that providethe stretchable surface.

In a twenty-third embodiment, the present disclosure provides the methodof the twentieth or twenty-first embodiment, wherein the stretchablesurface is a sleeve connected to the two rotating diverging disks.

In a twenty-fourth embodiment, the present disclosure provides themethod of any one of the twentieth to twenty-third embodiments, whereina distance between the two diverging disks' peripheral surfaces at apoint of greatest separation is at least 25 percent greater than adistance between the two diverging disks' peripheral surfaces at a pointof least separation.

In a twenty-fifth embodiment, the present disclosure provides the methodof any one of the twentieth to twenty-fourth embodiments, wherein theroller is an idler roller.

In a twenty-sixth embodiment, the present disclosure provides the methodof any one of the twentieth to twenty-fifth embodiments, wherein afterat least some of the multiple strands are at least partially separated,the method further comprises running the slit web over a second rollercomprising two rotating diverging disks that are laterally spaced andhave a stretchable surface between them that stretches in thecross-machine direction for a portion of a rotation of the two rotatingdiverging disks, wherein at least a portion of at least some of themultiple strands of the slit web are further separated on the secondroller.

In a twenty-seventh embodiment, the present disclosure provides themethod of any one of the first to nineteenth embodiments, wherein thestretchable surface is stretched on a conveyor belt apparatus.

In a twenty-eighth embodiment, the present disclosure provides themethod of any one of the first to twenty-seventh embodiments, furthercomprising heating the slit web before, while, or after at least some ofthe multiple strands are at least partially separated.

In a twenty-ninth embodiment, the present disclosure provides the methodof the twenty-eighth embodiment, wherein heating anneals the slit webafter at least some of the multiple strands are at least partiallyseparated.

In a thirtieth embodiment, the present disclosure provides the method ofthe twenty-eighth or twenty-ninth embodiment, wherein heating comprisesrunning the slit web onto a rotating heated cylinder after at least someof the multiple strands are at least partially separated.

In a thirty-first embodiment, the present disclosure provides the methodof the twenty-eighth or twenty-ninth embodiment, wherein heating theslit web comprises using non-contact heating.

In a thirty-second embodiment, the present disclosure provides themethod of any one of the first to thirty-first embodiments, wherein atleast some of the multiple strands are at least partially separated suchthat that the width of the slit web is up to 200 percent greater afterthe slit web contacts the stretchable surface.

In a thirty-third embodiment, the present disclosure provides the methodof any one of the first to thirty-second embodiments, wherein the firstdirection is the machine direction.

In a thirty-fourth embodiment, the present disclosure provides themethod of any one of the first to thirty-third embodiments, whereinthere is no macroscopic stretch-induced molecular orientation in theslit web in the cross-direction after at least some of the multiplestrands are at least partially separated.

In a thirty-fifth embodiment, the present disclosure provides the methodof any one of the first to thirty-fourth embodiments, further comprisingdirecting the slit web onto a high-friction surface after at least someof the multiple strands are at least partially separated.

In a thirty-sixth embodiment, the present disclosure provides the methodof the thirty-fifth embodiment, wherein the high-friction surface is aheated high-friction roller.

In a thirty-seventh embodiment, the present disclosure provides themethod of the thirty-fifth embodiment, wherein the high-friction surfaceis a chilled high-friction roller.

In a thirty-eighth embodiment, the present disclosure provides themethod of any one of the first to thirty-seventh embodiments, furthercomprising directing the slit web onto a rotating chilled cylinder.

In a thirty-ninth embodiment, the present disclosure provides the methodof any one of the first to thirty-eighth embodiments, further comprisinglaminating the slit web to a carrier after at least some of the multiplestrands are at least partially separated.

In a fortieth embodiment, the present disclosure provides the method ofthe thirty-ninth embodiment, wherein the carrier is a nonwoven web.

In a forty-first embodiment, the present disclosure provides the methodof the thirty-ninth or fortieth embodiment, wherein the carrier isprovided with a layer of adhesive, wherein the slit web is bonded to thecarrier with the adhesive to form a laminate, and wherein the adhesiveis exposed between the multiple strands in the laminate.

In a forty-second embodiment, the present disclosure provides the methodof any one of the thirty-ninth to forty-first embodiments, wherein thelaminate is directed through a nip downweb from where the slit web isbonded to the carrier.

In a forty-third embodiment, the present disclosure provides a method ofincreasing a width of a polymeric netting, the method comprising:

providing a polymeric netting having a length in a machine direction;and

running the polymeric netting in the machine direction onto astretchable surface, wherein the polymeric netting is in contact withthe stretchable surface for a path length in the machine direction,wherein for at least a portion of the path length, the stretchablesurface is stretching in the cross-machine direction, and whereintraction between the polymeric netting and the stretchable surfaceduring stretching increases the width of at least a portion of thepolymeric netting in the cross-machine direction.

In a forty-fourth embodiment, the present disclosure provides the methodof the forty-third embodiment, wherein the polymeric netting has a widthafter contacting the stretchable surface that is at least five percentgreater than its width before it contacts the stretchable surface.

In a forty-fifth embodiment, the present disclosure the method of theforty-third or forty-fourth embodiment, wherein the polymeric nettingcomprises mechanical fastening elements on at least one major surface.

In a forty-sixth embodiment, the present disclosure provides the methodof the forty-fifth embodiment, wherein the polymeric netting comprisesloops.

In a forty-seventh embodiment, the present disclosure provides themethod of the forty-fifth embodiment, wherein the mechanical fasteningelements are male fastening elements comprising upstanding posts havingbases attached to the polymeric netting.

In a forty-eighth embodiment, the present disclosure provides the methodof the forty-seventh embodiment, wherein the male fastening elementsfurther comprise caps distal from the polymeric netting.

In a forty-ninth embodiment, the present disclosure provides the methodof any one of the forty-fifth to forty-eighth embodiments, wherein thepolymeric netting is arranged so that the mechanical fastening elementsface away from the stretchable surface.

In a fiftieth embodiment, the present disclosure provides the method ofany one of the forty-fifth to forty-eighth embodiments, wherein thepolymeric netting is arranged so that the mechanical fastening elementsface toward the stretchable surface.

In fifty-first embodiment, the present disclosure provides the method ofthe fiftieth embodiment, wherein the polymeric netting is coated withadhesive on its surface opposite the mechanical fastening elements.

In a fifty-second embodiment, the present disclosure provides the methodof any one of the forty-third to fifty-first embodiments, wherein thestretchable surface does not have a support surface contacting thestretchable surface on a side opposite a side of the stretchable surfacethat contacts the polymeric netting.

In a fifty-third embodiment, the present disclosure provides the methodof any one of the forty-third to fifty-second embodiments, wherein thepolymeric netting comprises multiple strands of a slit web attached toeach other at intact bridging regions and separated from each otherbetween at least some of the intact bridging regions.

In a fifty-fourth embodiment, the present disclosure provides the methodof any one of the forty-third to fifty-third embodiments, whereinstretchable surface comprises an elastomer.

In a fifty-fifth embodiment, the present disclosure provides the methodof any one of the forty-third to fifty-fourth embodiments, wherein thestretchable surface is provided by at least one stretchable band,stretchable tubing, at least one coiled spring, or a combinationthereof.

In a fifty-sixth embodiment, the present disclosure provides the methodof any one of the forty-third to fifty-fifth embodiments, wherein thepolymeric netting is run onto at least two different stretchablesurfaces.

In a fifty-seventh embodiment, the present disclosure provides themethod of any one of the forty-third to fifty-sixth embodiments, whereinrunning the polymeric netting in the machine direction comprises runningthe polymeric netting onto a roller comprising two rotating divergingdisks that are laterally spaced and have the stretchable surface betweenthem that stretches in the cross-machine direction for a portion of arotation of the two rotating diverging disks.

In a fifty-eighth embodiment, the present disclosure provides the methodof the fifty-seventh embodiment, wherein at least one diverging disk hasan angle to the machine direction of at least one degree.

In a fifty-ninth embodiment, the present disclosure provides the methodof the fifty-seventh or fifty-eighth embodiment, wherein there aremultiple stretchable bands, stretchable tubing, multiple coiled springs,or a combination thereof attached to the diverging disks that providethe stretchable surface.

In a sixtieth embodiment, the present disclosure provides the method ofthe fifty-seventh or fifty-eighth embodiment, wherein the stretchablesurface is a sleeve connected to the two rotating diverging disks.

In a sixty-first embodiment, the present disclosure provides the methodof any one of the fifty-seventh to sixtieth embodiments, wherein adistance between the two diverging disks' peripheral surfaces at a pointof greatest separation is at least 25 percent greater than a distancebetween the two diverging disks' peripheral surfaces at a point of leastseparation.

In a sixty-second embodiment, the present disclosure provides the methodof any one of the fifty-seventh to sixty-first embodiments, wherein theroller is an idler roller.

In a sixty-third embodiment, the present disclosure provides the methodof any one of the fifty-seventh to sixty-second embodiments, furthercomprises running the polymeric netting over a second roller comprisingtwo rotating diverging disks that are laterally spaced and have astretchable surface between them that stretches in the cross-machinedirection for a portion of a rotation of the two rotating divergingdisks, and wherein traction between the polymeric netting and thestretchable surface of the second roller during stretching furtherincreases the width of at least a portion of the polymeric netting inthe cross-machine direction.

In a sixth-fourth embodiment, the present disclosure provide the methodany one of the forty-third to fifty-sixth embodiments, wherein thestretchable surface is stretched on a conveyor belt apparatus.

In a sixty-fifth embodiment, the present disclosure provides the methodof any one of the forty-third to sixty-fourth embodiments, furthercomprising heating the polymeric netting before, during, or afterincreasing the width of the polymeric netting.

In a sixty-sixth embodiment, the present disclosure provides the methodof the sixty-fifth embodiment, wherein heating anneals the polymericafter the width of the polymeric netting is increased.

In a sixty-seventh embodiment, the present disclosure provides themethod of the sixty-fifth or sixty-sixth embodiment, wherein heatingcomprises running the polymeric netting onto a rotating heated cylinderafter the width of the polymeric netting is increased.

In a sixty-eighth embodiment, the present disclosure provides the methodof the sixty-fifth or sixty-sixth embodiment, wherein heating thepolymeric netting comprises using non-contact heating.

In a sixty-ninth embodiment, the present disclosure provides the methodof any one of the forty-third to sixty-eighth embodiments, wherein widthof the polymeric netting is increased up to 200 percent.

In a seventieth embodiment, the present disclosure provides the methodof any one of the forty-third to sixty-ninth embodiments, wherein thefirst direction is the machine direction.

In a seventy-first embodiment, the present disclosure provides themethod of any one of the forty-third to seventieth embodiments, whereinthere is no macroscopic stretch-induced molecular orientation in thepolymeric netting in the cross-direction after the width of thepolymeric netting is increased.

In a seventy-second embodiment, the present disclosure provides themethod of any one of the forty-third to seventy-first embodiments,further comprising directing the polymeric netting onto a high-frictionsurface after the width of the polymeric netting is increased.

In a seventy-third embodiment, the present disclosure provides themethod of the seventy-second embodiment, wherein the high-frictionsurface is a heated high-friction roller.

In a seventy-fourth embodiment, the present disclosure provides themethod of the seventy-second embodiment, wherein the high-frictionsurface is a chilled high-friction roller.

In a seventy-fifth embodiment, the present disclosure provides themethod of any one of the forty-third to seventy-fourth embodiments,further comprising directing the polymeric netting onto a rotatingchilled cylinder.

In a seventy-sixth embodiment, the present disclosure provides themethod of any one of the forty-third to seventy-fifth embodiments,further comprising laminating the polymeric netting to a carrier afterthe width of the polymeric netting is increased.

In a seventy-seventh embodiment, the present disclosure provides themethod of the seventy-sixth embodiment, wherein the carrier is anonwoven web.

In a seventy-eighth embodiment, the present disclosure provides themethod of the seventy-sixth or seventy-seventh embodiment, wherein thecarrier is provided with a layer of adhesive, wherein the polymericnetting is bonded to the carrier with the adhesive to form a laminate,and wherein the adhesive is exposed between intersecting strands in thepolymeric netting.

In a seventy-ninth embodiment, the present disclosure provides themethod of any one of the seventy-sixth to seventy-eighth embodiments,wherein the laminate is directed through a nip downweb from where thepolymeric netting is bonded to the carrier.

This disclosure is not limited to the above-described embodiments but isto be controlled by the limitations set forth in the following claimsand any equivalents thereof. This disclosure may be suitably practicedin the absence of any element not specifically disclosed herein.

What is claimed is:
 1. A method of increasing a width of a polymericnetting, the method comprising: providing a polymeric netting having alength in a machine direction; and running the polymeric netting in themachine direction onto a stretchable surface, wherein the polymericnetting is in contact with the stretchable surface for a path length inthe machine direction, wherein for at least a portion of the pathlength, the stretchable surface stretches in the cross-machinedirection, wherein traction between the polymeric netting and thestretchable surface during stretching increases a width of at least aportion of the polymeric netting in the cross-machine direction, andwherein the stretchable surface is provided by at least one stretchableband, stretchable tubing, at least one coiled spring, or a combinationthereof.
 2. The method of claim 1, wherein the polymeric netting has awidth after contacting the stretchable surface that is at least fivepercent greater than its width before it contacts the stretchablesurface.
 3. The method of claim 1, wherein the polymeric nettingcomprises mechanical fastening elements on at least one major surface.4. The method of claim 3, wherein the mechanical fastening elements aremale fastening elements comprising upstanding posts having basesattached to the polymeric netting.
 5. The method of claim 3, wherein thepolymeric netting is coated with adhesive on its major surface oppositethe mechanical fastening elements.
 6. The method of claim 1, wherein thestretchable surface does not have a support surface contacting thestretchable surface on a side opposite a side of the stretchable surfacethat contacts the polymeric netting.
 7. The method of claim 1, furthercomprising directing the polymeric netting onto a high-friction surfaceafter the width of at least a portion of the polymeric netting isincreased.
 8. The method of claim 1, further comprising laminating thepolymeric netting to a carrier after the width of at least a portion ofthe polymeric netting is increased.
 9. The method of claim 8, whereinthe carrier is provided with a layer of adhesive, and wherein thepolymeric netting is bonded to the carrier with the adhesive to form alaminate.
 10. The method of claim 1, wherein stretchable surfacecomprises an elastomer.
 11. A method of increasing a width of apolymeric netting, the method comprising: providing a polymeric nettinghaving a length in a machine direction; and running the polymericnetting in the machine direction onto a stretchable surface, wherein thepolymeric netting is in contact with the stretchable surface for a pathlength in the machine direction, wherein for at least a portion of thepath length, the stretchable surface stretches in the cross-machinedirection, wherein traction between the polymeric netting and thestretchable surface during stretching increases a width of at least aportion of the polymeric netting in the cross-machine direction, andwherein running the polymeric netting in the machine direction comprisesrunning the polymeric netting onto a roller comprising two rotatingdiverging disks that are laterally spaced and have the stretchablesurface between them that stretches in the cross-machine direction for aportion of a rotation of the two rotating diverging disks.
 12. Themethod of claim 11, wherein there are multiple stretchable bands,stretchable tubing, multiple coiled springs, or a combination thereofattached to the diverging disks that provide the stretchable surface.13. The method of claim 11, wherein the stretchable surface is a sleeveconnected to the two rotating diverging disks.
 14. The method of claim11, wherein a distance between the two diverging disks' peripheralsurfaces at a point of greatest separation is at least 25 percentgreater than a distance between the two diverging disks' peripheralsurfaces at a point of least separation.
 15. The method of claim 11,wherein stretchable surface comprises an elastomer.
 16. The method ofclaim 11, wherein the stretchable surface does not have a supportsurface contacting the stretchable surface on a side opposite a side ofthe stretchable surface that contacts the polymeric netting.
 17. Themethod of claim 11, wherein the polymeric netting comprises mechanicalfastening elements on at least one major surface.
 18. The method ofclaim 11, further comprising directing the polymeric netting onto ahigh-friction surface after the width of at least a portion of thepolymeric netting is increased.
 19. The method of claim 11, furthercomprising laminating the polymeric netting to a carrier after the widthof at least a portion of the polymeric netting is increased.
 20. Themethod of claim 19, wherein the carrier is provided with a layer ofadhesive, and wherein the polymeric netting is bonded to the carrierwith the adhesive to form a laminate.